Design embossed high luster finish material



Patented Oct. 4, 1938 UNITED STATES nssrcn mmossso man ws'ma mmsn m'mam.

Brady Armor and John J. Walsh, Ncwbnrgh, N. Y., assignors "to E. I. duPont de Nemours & Company, Wilmington, DeL', a corporation of DelawareNo Drawing.

Application April 10, 1936, Serial 5 Claims. (Cl. ill-67.9)

This invention relates to a process for producing high luster finishembossedfiexible sheet material and more particularly to a process forproducing high luster finish embossed coated textile material.

High luster finishes on such fiexible materials as leather, coatedfabrics, coated paper, etc., are well known and are in demand by thetrade in the various industries. Such materials have been producedlargely with a smooth or unembossed surface. Embossing such high lustermaterial usually destroys or mars the high luster of the surface. Incertain types of cellulose derivative composition coated fabrics a highluster embossed surface is sometimes obtained by applying an unpigmentedcellulose derivative composition to the pigmented cellulose compositionpreviously applied to the fabric, the coated material is then embossedand finally a coating is applied of the same unpigmented cellulosederivative composition as was applied before the material was embossed.This last composition is necessary to restore the luster of the surfacewhich is marred by the embossing operation. The application of theunpigmented cellulose derivative composition after the embossingrestores the luster to the depressed as well as the undepressed portionsof the embossed design.

This is not always desirable and further the final application of theunpigmented composition adds to the cost of the finished material andthe damage hazard is increased in working on a product which issubstantially in its finished condition. When such material is damagedin this operation it cannot be easily treated to make it satisfactoryfor sale as first class material. As indicated above, it is alsodesirable in many instances to produce a material with an embossedsurface which possesses a high luster on the undepressed portion of thedesign and a dull effect on the depressed portion of the design. Themeans used in the present state of the art to produce such a dull effectin the depressed portion of the design of the embossing mars or destroysto a greater or lesserdegree the high luster which is desired on theundepressed portion of the grain.

This invention therefore has as an object the provision of a process forproducing a design embossed surface on a flexible base material as acoated fabric which has a high luster on the undepressed portion of thedesign and a dull contrasting effect in the depressed portion of theembossed design.

This object is accomplished by applying a film of an unpigmentedcellulose derivative-softener composition on a previously appliedpigmented cellulose derivative coating on a fabric or similar flexiblebase material and then superimposing a final coating of a nonpigmentednonsoftened cellulose derivative composition after which the thus coatedmaterial is embossed by suitable means so that the relief on theembossing plate just pierces the non-pigmented non-softened cellulosederivative composition film in the depressed portion of the design.

The following example is given as an embodiment but it is understoodthat the invention is not limited thereby except as indicated in theappended claims.

To a fabric of a so-called sateen weave and weighing approximately 14.3ounces per linear yard 53 inches in width is applied a plurality ofcoats of a cellulose derivative composition having the followingformula:

Composition No. 1

Per cent by weight Cellulose nitrate 13. 5 Pigment 15. 7 Softener 28. 1Ethyl acetate l7. 1 Ethyl alcohol 25. 6

Per cent by weight Cellulose nitrate 17. 3 Softener 17. 3

Ethyl acetate 26.2 Ethyl alcohol 39. 2

This composition is applied to the. extent of approximately 4.3 ouncesper linear yard which corresponds to approximately 1.5 ounces of thenon-volatile components or solids. As a final coating there is applied acomposition of the following formula: I

Composition N0. 3

- Per cent by weight Cellulose nitrate 8. 3 Ethyl acetate 36. 9 Ethylalcohol 54. 8

This composition is applied to the extent of approximately one-halfounce of solids per linear yard which is equivalent to approximately 6ounces of the composition as given above.

The compositions are applied by conventional means known in the art ofcoating flexible base materials. a convenient means being by a doctorknife. The individual coats are usually subjected The coatingcompositions used may likewise be prepared according to conventionalmethods. The coated material prepared as described possesses a highluster smooth surface. It is now subjected to an embossing operation toimpart a design to the finished product. Just sufiicient pressure isapplied during the dwell of the embossing plate against the high lustersurface to cause the sharp relief on the embossing plate to just piercethe non-softened non-pigmented cellulose derivative film and not piercethe nonpigmented but softened cellulose derivative intermediate coat.The steam pressure in the head of the embossing press should be betweenapproximately 10 and 30 pounds. After the embossing operation theproduct is finished and a material is obtained with an embossed designin which the undepressed portion has a high luster and the depressedportions are dull, producing a pleasing effect against the high lusterportions of the surface of the material.

The embossing step may be carried out by means of rolls instead ofplates as indicated above. The principle of the process is the same whenrolls are used; that is, the pressure between the rolls must be justenough to cause the sharp relief on the embossing roll to just piercethe nonsoftened non-pigmented cellulose derivative film and not piercethe non-pigmented, but softened cellulose derivative intermediate coat.

The invention is not limited to the use of the coated sateen fabricnoted in the description. Other fabrics such as sheetings, ducks,drills, broken twills and moleskins may be used. Further such flexiblebase materials as felted fabrics, paper, leather, etc., aresatisfactory. The amount of the pigmented and softened coatingcomposition as well as the amounts of the nonpigmented compositionsapplied to the flexible base may be varied within rather wide limits andsuch limits will be readily apparent to those skilled in the art ofcoating flexible bases. The preferred results will however be obtainedwith a relatively heavy film particularly with respect to the pigmentedand softened portion of the film. The amount and kind of theconstituents of the various compositions used to produce the coatingsmay be varied within a range which will be evident to those skilled inpreparing and using such compositions.

In producing the embossed design the pressure which is applied to thehigh luster surface should be just sufficient to break the non-pigmentednonsoftened upper film of the coated base material. The pressure may ofcourse vary with different types of film, thickness of film, etc., andthe optimum pressure to use may be readily determined by experiment. Iftoo great a pressure is used the high luster on the undepressed portionof the design will be marred or destroyed. Just sufficient pressureshould be used to produce the embossed design so that the depressedportions will be dull in contrast to the luster of the undepressedportion. A variety of embossed designs may be used. The use of suchdesigns, however, which have relatively large undepressed areas with arather sharp edge on the contour of the undepressed area produce themost pleasing effects and the most satisfactory results.

In the examples, the invention has been illustrated by cellulose nitrateas the cellulose derivative. It is not limited to this ester since othercellulose derivatives may be substituted for the cellulose nitrate inthe formulas in greater or lesser amounts as will be apparent to thoseskilled in the art. It will likewise be apparent that resins may beincluded in the formula in which they may function either as afilm-forming component or as a softener.

The invention is applicable to the production of embossed designs onhigh glaze finishes on coated flexible base material. Such materialsfind exten-. sive use wherever smooth high glaze finishes have been usedin the past. Because of the pleasing designs and the effects produced bythe process many uses will suggest themselves to those familiar with theapplication of such products.

It will be seen from the foregoing that a process is presented whichdoes not require the application of any composition or any othertreatment to produce a contrast in luster between the depressed portionsand the undepressed portions of an embossed design on a high glazecoated flexible base material. Further, the process does not mar ordestroy the high luster on the undepressed portions of the designembossed finished product.

It is apparent that many widely different embodiments of this inventionmay be made without departing from the spirit and scope thereof; and,therefore, it is not intended to be limited except as indicated in theappended claims.

We claim:

1. Process for preparing an embossed coated fabric of high luster on thehills and a dull luster in the valleys which comprises applying to awoven fabric a pigmented composition containing cellulose nitrate, asoftener and volatile solvents, the said softener being present inamount about twice that of the cellulose nitrate allowing the saidcomposition to dry and applying thereto a composition containingapproximately equal parts of cellulose nitrate and a softener dispersedin a volatile organic liquid, allowing the said organic liquid toevaporate, and applying a surface coat of cellulose nitrate andembossing the said fabric under a pressure of about 10 to 30 lbs. persquare inch with an embossing member having sharp relief portions whichare relatively small compared to the depression areas, whereby thesurface coat only is pierced by the embossing member.

2. The processof preparing high luster embossed coated fabrics whichcomprises applying to a suitable fabric a composition having theapproximate following formula:

allowing the thus coated fabric to dry, applying to the first coating acomposition having the approximate formula:

Per cent by weightv Cellulose nitrate Softener Ethyl acetate Ethylalcohol allowing the resultant to dry, applying over the second coat asurface coat of a composition having the approximate following formula:

Per cent by weight Cellulose nitrate 8.3 Ethyl acetate 36.9 Ethylalcohol 54.8

allowing the resultant to dry and thereafter embossing, the embossingbeing carried out under such pressure that only the surface coating ispierced by the embossing member.

3. The product obtainable by applying to a suitable fabric a compositionhaving the approximate following formula:

Per cent by weight Cellulose nitrate 13.5 Pi gmeni: 15.7 Softener 28.1Ethyl acetate 17.1 Ethyl alcohol 25.6

allowing the thus coated fabric to dry, applying to the first coating acomposition having the approximate formula Per cent by weight Cellulosenitrate 17.3 Softener--- 17.3 Ethyl acetate 26.2 Ethyl alcohol 39.2

allowing the resultant to dry, applying over the second coat a surfacecoat of a composition having the approximate following formula: v

Per cent byiweight Cellulose nitrate 8.3 Ethyl acetat 36.9 Ethyl alcohol1 54.8

allowing the resultant to dry and thereafter embossing, the embossingbeing carried out under such pressure that only the surface coating ispierced by the embossing member.

4. The product obtainable by applying to a suitable fabric a compositionhaving the approxi mate following formula:

Per cent by weight Cellulose nitrate 13.5 Pigme 15.7 Softener 28.1 Ethylacetate 17.1 Ethyl alcohol 25.6

. 100.0 in an amount approximating 35 ounces per linear yard of basefabric 53 inches wide, allowing the thus coated fabric to dry,applyingto the first coating a composition having the approximateformula:

.Per cent by weight Cellulose nitrate 17.3

Softener 17.3 Ethyl acetate 26.2 Ethyl alcohoL 39.2

in an amount approximating 4.3 ounces per linear yard of base fabric 53inches wide, allowing the resultant to dry, applying over the secondcoat a.

surface coat of a composition having the approximate following formula:

Per cent byweight Cellulose nitrate 8.3 .Ethyl acetate 36.9 Ethylalcohol 54.8

Cellulose nitrate 13.5 Pigme 15.7 Softener 28.1 Ethyl acetate 17.1 Ethylalcohol 25.6

in an amount approximating 35 ounces per linear yard of base fabric 53inches wide, allowing the thus coated fabric to dry, applying to thefirst .coating a composition having the approximate formula:

Per cent by weight Cellulose nitr 17.3 Softener 17.3 Ethyl aceta 26.2Ethyl alcohol--- 39.2

in an amount approximating 4.3 ounces per linear yard of base fabric 53inches wide, allowing the resultant to dry, applying over the's'econdcoat a surface coat of a composition having the approximate followingformula:

Per cent by weight a Cellulose nitrate Ethyl aceta 36.9 Ethyl alcohol-54.8

100.0 in an amount approximating Bounces per linear yard of base fabric53 inches wide, allowing the resultant to-dry and thereafter embossingunder a pressure of 10 to 30 pounds per square incgi/ BRADY s. lumen.

JOHN J.'.WAI8H.

